Display assemblies and methods for applying the same to vulcanized rubber articles

ABSTRACT

Display assemblies as disclosed herein are configured for attachment with a vulcanized rubber article and are provided in the form of different material layers. Display assemblies generally comprise one or more display layers of elastomeric material configured to provide a desired display indicia, an intermediate layer formed from an elastomeric material different from that of the one or more display layers, and an adhesive layer wherein the intermediate layer is interposed between the adhesive layer and the one or more display layers. The one more display layers may be configured to act together or separately to provide a desired display indicia to provide a desired visual display or feature on the surface of the vulcanized rubber article, which may be a sidewall surface of a tire.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. Provisional PatentApplication No. 62/153,441, filed on Apr. 27, 2015, which is herebyincorporated by reference in its entirety.

FIELD

This disclosure relates to display assemblies and methods for applyingthe same to a vulcanized rubber article.

BACKGROUND

The use of decals or the like for use on vulcanized rubber articles suchas a sidewall portion of a tire or the like is somewhat known in theart, e.g., in the form of lettering and/or designs, for the purpose ofadding features of aesthetic appearance, branding or the like to thevulcanized article containing the same. Such decals known in the artadapted for such uses are constructed in a manner that is eitherintended for temporary rather than permanent service, and/or that isadapted for application at a point of manufacture of the vulcanizedarticles. For example, traditional techniques for establishing tiresidewall markings involve extrusion or molding of black rubber and oftenthe addition of colored inks which are cured in parallel with the tireduring the vulcanization process. This process, though well establishedand scaled for industry, requires significant investment in materials,equipment and labor along with sizable wastage costs resulting fromvoids, blemishes and other defective designs. In addition, thistechnique is extremely limiting in terms of customizable designs due tomolds and dies required to achieve the desired variations, and thus theavailability of this customization to individual consumers and evencustomers internal to the industry is extremely limited.

It is, therefore, desired that display assemblies for use with avulcanized article be constructed in a manner that permits not onlyvariation in the nature of the display itself, e.g., the nature of theindicia be it one or a combination of characters, designs, emblems, andcombinations thereof and the like, but variation in the method ofapplying the same so as to facilitate application as part of orsubsequent to the manufacture of the vulcanized article. It is furtherdesired that such display assembly be constructed in a manner thatfacilitates use of the same once applied for a long duration, e.g., thelife of the vulcanized article. It is still further desired that suchdisplay assembly be constructed in a manner so as to facilitate suchlong-term without sacrificing the integrity and aesthetic appearance ofthe display assembly.

SUMMARY

Display assemblies as disclosed herein are specially constructed forattachment with a vulcanized rubber article to provide a desired displayindicia, which may be a visual display or a feature that is visually orotherwise detectable. Display assemblies as disclosed herein generallycomprise a composite of different material layers specially engineeredto provide a desired display indicia in a manner that will last a longtime on the vulcanized rubber article. Display assemblies comprise oneor more display layers of elastomeric material configured to provide adesired display indicia, an intermediate layer formed from anelastomeric material different from that of the one or more displaylayers, and an adhesive layer, wherein the intermediate layer isinterposed between the adhesive layer and the one or more displaylayers.

In an example, the adhesive layer is formed from a material forming achemical bonding between the display assembly and the surface of thevulcanized rubber article. The display assembly may comprise two displaylayers, wherein one display layer may be disposed beneath anotherdisplay layer, and wherein the display layers may each be of a differentcolor and/or be patterned or otherwise configured so as to provide adesired display indicia by interaction of the two. An intermediateadhesive layer may be interposed between one or more display layers andthe intermediate layer. If desired, a transparent protective layer maybe disposed over the one or more display layers, forming an outermostsurface of the display assembly. The display assembly may comprise acavity disposed therein that may include an element disposed therein.

Display assemblies as disclosed herein may be attached to the surface ofa vulcanized article by applying an adhesive material to form theadhesive layer, wherein the adhesive layer may be applied to one or bothof the surface of the vulcanized article and an underlying surface ofthe display assembly, and placing a display assembly into contact withthe surface of the vulcanized rubber article to form a bond between thedisplay assembly and surface. In an example, a stencil may be used toensure placement of the display assembly in a desired arrangement, or atransfer carrier may be used to provide the display assembly in thedesired arrangement for placement onto the surface.

Display assemblies as disclosed herein are constructed provideflexibility in the nature of the display indicia itself, and variationin the method of applying the same so as to facilitate application aspart of or subsequent to the manufacture of the vulcanized article.Also, display assemblies as disclosed herein are constructed in a mannerthat facilitates use of the same once applied for a long duration, e.g.,the life of the vulcanized article, without sacrificing the integrityand/or aesthetic appearance of the display assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of display assemblies andmethods for making the same as disclosed herein will be appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a perspective view of an example display assembly as disclosedherein as attached to a vulcanized article in the form of a tiresidewall;

FIG. 2 is a cross-sectional side view of a single display layerembodiment three-layer assembly ‘20’ as disclosed herein, wherein layer‘22’ is defined as the outermost aesthetic layer which is vulcanized fora permanent bond along underside surface ‘28’ to a shock absorbingbarrier layer ‘24’ layered with an adhesive layer ‘26’ for permanentlybonding to the vulcanized rubber article;

FIG. 3 is a cross-sectional side view of a second example displayassembly as disclosed herein, wherein a double display layer embodimentcomprises a four-layer assembly ‘30’ having a first display layer ‘31’as the outermost aesthetic display layer which is vulcanized for apermanent bond to a second display layer ‘33’ which is furthervulcanized to a shock absorbing barrier layer ‘36’ layered with anadhesive layer ‘38’ for permanently bonding to the vulcanized rubberarticle;

FIG. 4A is a cross-sectional side view of a third example displayassembly as disclosed herein comprising a single display layer withdouble layer adhesive and barrier four-layer assembly ‘40’ having layer‘48’ as the outermost aesthetic display layer which is bonded with ashock absorbing barrier layer ‘44’ using a permanent adhesive layer ‘50’and the barrier layer ‘44’ is layered with another adhesive layer ‘46’for permanently bonding to the vulcanized rubber article;

FIG. 4B is a cross-sectional side view of an alternative third exampledisplay assembly as disclosed herein comprising dual display layers withdouble layer adhesive and barrier—five layer assembly ‘42’ having layer‘45’ as the outermost display layer which is bonded with a second orintermediate display layer ‘49’ using an intermediate adhesive layer‘47’ and the intermediate display layer is bonded with a shock absorbingbarrier layer ‘51’ that is layered with another adhesive layer ‘53’ forpermanently bonding to the vulcanized rubber article;

FIG. 5 is a cross sectional side view of a fourth example displayassembly as disclosed herein comprising a double display layer ‘52’embodiment five-layer assembly ‘50’ having layer '57 as the outermostaesthetic display layer which is vulcanized for a permanent bond to asecond display layer ‘59’ which is bonded with a shock absorbing layer‘56’ using a permanent adhesive layer ‘54’ and the barrier layer ‘56’ islayered with another adhesive layer ‘58’ for permanently bonding to thevulcanized rubber article;

FIG. 6 is a cross section side view of a fifth example display assemblyas disclosed herein comprising a double display layer ‘64’ four-layerembodiment assembly ‘60’ having layer ‘62’ as a protective over-laminatelayer disposed over all or a portion of the display layer(s) ‘67’ and‘69’ vulcanized to a shock absorbing barrier layer ‘66’ and layered witha permanent adhesive layer ‘68’ for bonding to the vulcanized rubberarticle;

FIG. 7 is a cross section side view of a fifth example display assemblyas disclosed herein comprising a multiple layer assembly ‘70’ withcavity ‘78’ having an embedded functional element ‘79’ within theconstruction of the assembly, wherein the assembly ‘70’ comprises adouble display layer ‘72’ with aesthetic layers 80 and 82 which alsoserve as perimeter layers to the cavity ‘78’, wherein the display layersare vulcanized and bonded to a barrier layer ‘76’ with a permanentadhesive layer ‘74’ and having another layer of permanent adhesive ‘77’for bonding to the vulcanized rubber article; and

FIGS. 8A to 8H are schematic views of different steps of an examplemethod for attaching a display assembly as disclosed herein to sidewallof a vulcanized rubber article in the form of a tire.

DETAILED DESCRIPTION

Display assemblies or constructions as disclosed herein are speciallyengineered to facilitate attachment to a vulcanized article, which mayinclude but is not limited to tires, mud flaps, or any other member orelement that is vulcanized or made from vulcanized rubber. Displayassemblies as disclosed herein are provide for the purpose of providinga desired aesthetic appearance, product identification, tracking,branding, advertising, to provide a desired functional aspect to thevulcanized article, and the like to such vulcanized article. In anexample, display assemblies as disclosed herein may comprise one or moreelastomeric display layers providing the desired display image orfunction, an intermediate or barrier layer formed of an elastomericmaterial, and a layer of curable adhesive that is formed from a materialcapable of forming a strong adhesion bond with a surface of thevulcanized article. The display assemblies as disclosed herein mayoptionally comprise an adhesive layer interposed between the displaylayer and one or more of the barrier layers, and may comprise variouscombinations of one or more display layers, one or more intermediate orbarrier layers, and one or more adhesive layers as called for by thespecific end use application. Further, display assemblies as disclosedherein may optionally comprise an overcoat or transparent protectivelayer disposed over the display layer.

FIG. 1 illustrates an example display assembly or construction 10 asdisclosed herein as attached to a vulcanized article 12. Displayassemblies as disclosed herein can be used with a variety of differentlyconfigured vulcanized articles, wherein a unifying feature of sucharticles or attachment substrates is that they are formed from or havean outer surface comprising vulcanized rubber. In an example, thevulcanized article may be a rubber tire, wherein the display assembly isconfigured to be adhered to a portion of the rubber tire. In an example,the portion of the rubber tire may be a sidewall 14 of the tire. While aparticular configuration or type of vulcanized article, and a particularportion of such article, has been described as being useful as thearticle or substrate for adhering display assemblies as disclosed hereinthereto, it is to be understood that the use of display assemblies asdisclosed herein is not to be limited to such types of vulcanizedarticles and/or portion of the same, and such is provided for purpose ofexample and reference.

The display assembly 10 is provided in a desired form or configurationdepending on the desired display indicia or function intended, which canbe in the form of a letter, numeral, symbol, design, pattern, logo,insignia, or the like that may be continuous or non-continuous in formdepending on the particular end-use application. For example, thedisplay assembly 10 can be configured in the shape of a letter and anumber of the display assemblies can be used alone or in conjunctionwith one or more other display assemblies that may be continuous withone another or separate from one another to provide a desired word,term, brand, logo, message, symbol, function or the like on a surface ofthe desired vulcanized article. For example, the display assembly 10 canbe configured as a continuous member that is disposed along an entireportion of the vulcanized article, e.g., such as a sidewall stripe orother form of continuous indicia, or only along a partial designatedportion of the vulcanized article.

In an example, each such display assembly 10 comprises one or moredisplay layers that provide an outer surface of the display assemblythat operates to visually provide the display image or indicia orfunction. The one or more display layers may be formed from anelastomeric material and may be configured to provide a desired displayimage or indicia on the outer surface of the display assembly 10. In anexample, the display layer may be constructed to have a desired colorand/or pattern, and or shape, and/or texture useful to provide a desireddisplay image or indicia or function. In an example, the display layermay be configured and/or colored and/or patterned to produce a desireddisplay image or indicia or function in conjunction with an underlyingbarrier layer. For example, the display layer may comprise one or moreopenings, e.g., a pattern of openings, and be of one color, and anunderlying barrier layer may be of another color making it viewablethrough the display layer openings to provide the desired display imageor indicia effect or function on the outer surface of the displayassembly. In the event that two or more display layers are used, thedifferent display layers may be configured and/or colored and/ortextured, and/or patterned differently for the purpose of being combinedtogether to provide the overall desired display image or indicia on theouter surface of the display assembly.

In an example, each display layer may be configured having a generallysimilar shape, e.g., in the shape of a letter, object, or numeral,wherein one of the display layers is provided in one color and anotherof the display layers is provided in a different color, and wherein thedisplay layers are sized differently, so when combined together theyoperate to provide a desired visual display effect. In an example, anupper display layer may be provided having a white color and a lowerdisplay layer beneath the upper display layer may be provided having ablack color, wherein the lower display layer is sized somewhat largerthan the upper display layer so as to enhance the visual effect providedby the combined display layers.

Alternatively, the display layer may be provided in the form of a singlelayer that is patterned or that has a desired cut-out segment, and thedesired display image is provided by contrast with an underlying otherlayer of the display assembly, e.g., which may be another display layeror a barrier layer. For example, the use of a patterned display layer inone color disposed on top of an underlying display layer or barrierlayer of another color may operate to provide a desired indicia, e.g.,that may be in the form of a barcode or the like used to provide anidentification or other type of purpose or function.

The display assembly 10 is adhered to or otherwise attached to a surfaceof the desired vulcanized article 12. In an example, the displayassembly is adhered to the vulcanized article in a manner as betterdescribed below that produces a strong and lasting attachment therewith,e.g., to facilitate attachment of the display assembly to the vulcanizedarticle for a long period of time which may be the service life of thevulcanized article. In an example, the display article is chemicallybonded with the vulcanized article. In an example, the display assemblymay be configured to match the contour or other surface geometry orsurface feature of the vulcanized article that it is to be used with.For example, in the event that the vulcanized article is a side wallsurface of a rubber tire, display assemblies as disclosed here may beconfigured to match the contour of the side wall surface to promote adesired optimal fit therewith when attached thereto.

FIG. 2 illustrates a first example display assembly 20 as disclosedherein comprising, moving from a surface portion of the display assembly20 to a portion attached to a vulcanized rubber article, a display layer22, an intermediate or barrier layer 24, and an adhesive layer 26. Asnoted above, the display assembly 20 is configured having a shape andsize as desired for a particular end-use application. In an example, thedisplay layer 22 is provided in the form of a single layer ofelastomeric material that may be colored, and/or patterned, and/ortextured as desired to provide a desired display image or indiciaviewable on the outer surface of the display assembly 20. In an exampleembodiment, elastomeric materials useful for forming the display layer22 include and are not limited to vulcanized rubber, natural rubber,SBR, nitrile rubber, neoprene rubber, rubber based or elastomeric inkhaving properties of aesthetic appeal of functional use, highelongation, UV and chemical resistance and abrasion resistance, andcombinations thereof. In an example, depending on the particular sizeand configuration of the display assembly 20, the display layer 22 mayhave a thickness greater than about 0.01 mm, of from about 0.01 to 10mm, 0.05 to 5 mm, 0.1 to 3 mm, and in a particular example about 0.4 mm.

In an example, the intermediate or barrier layer 24 is attached oradhered along an underside surface 28 of the display layer 22. In anexample, the intermediate layer 24 extends along and covers the entireunderside surface 28 of the display layer. Alternatively, theintermediate layer 24 may extend along a partial portion of the displaylayer underside surface 28, which is less than the entire portion andmore than a majority or 51 percent of the total area of the displaylayer underside surface 28. In an example, the intermediate or barrierlayer 24 is formed from a material capable of providing properties ofshock absorbance, elastomeric expansion and/or contraction propertiescompatible with the vulcanized rubber article that the display assemblyis to be attached therewith, and a desired degree of conformity betweenthe adjacent surfaces of the display layer and the outer surface of avulcanized rubber article (so as to maximize the surface contact areabetween the display assemble and vulcanized rubber article). Further, inthe example illustrated in FIG. 1, it is desired that the intermediatelayer 24 be formed from a material capable of being chemically bonded toor vulcanized with the display layer 22.

It is also desired that the intermediate or barrier layer 24 be formedfrom a material capable of acting as a barrier to minimize or preventthe migration of any unwanted constituents of the adhesive layer 26and/or the vulcanized rubber article may otherwise operate to damage ordegrade the design image and/or feature provided by the display layer22. In an example, the intermediate layer is formed from an elastomericmaterial. Elastomeric materials useful for forming the intermediatelayer 24 include and are not limited to gum rubber, vulcanized naturalrubber SBR, nitrile rubber, polyurethane, or comparable materials havingproperties of high elongation, conformity and chemical resistance tonotable mold release agents common in the vulcanized rubber of pneumatictires, and combinations thereof. In an example, depending on theparticular size and configuration of the display assembly 20, it isdesired that the intermediate layer 24 thickness be that which issufficient to enable the intermediate layer to function in theabove-described manner. The exact thickness of the intermediate layer isunderstood to vary depending on the particular type of material selectedfor the intermediate layer as well as the particular end-useapplication. In an example, the intermediate layer 24 may have athickness greater than about 0.008 mm, from about 0.008 to 10 mm, about0.01 to 5 mm, about 0.1 mm to 1.5 mm, and in a particular example ofabout 0.5 mm.

It is desired that the adhesive layer 26 be formed from a materialcapable of forming a chemically, heat-activated or otherwise permanentbonded attachment with the vulcanized rubber article. In an example, itis desired that the attachment be one having a service life that is thesame as the vulcanized rubber article so as to provide a permanentattachment therewith to permit the display assembly to functionthroughout the service life of the vulcanized article. The particulartype of material used for the adhesive layer may vary depending on theparticular display assembly application environment, e.g., in amanufacturing environment of where the vulcanized article is being made,or in a consumer environment subsequent to the manufacture of thevulcanized article. In an example, embodiment, such as one where thedisplay assembly is being attached to the vulcanized rubber article atthe point of the vulcanized rubber article being manufactured, theadhesive layer may be formed from a material capable of forming thedesired chemical bond or being vulcanized thereto under elevatedtemperature conditions, e.g., heat-activated adhesives. Such materialsinclude but are not limited to thermoplastic and thermoset adhesives,heat vulcanizing cements common in retread applications, water-based orsolvent based polymer polyurethane based adhesives, and combinationsthereof. Such application may also call for some degree of elevatedpressure being applied to the display assembly during adherence by theadhesive layer. In an example, such elevated pressure may be in therange of from about 3 to 100 Psi.

In an example, embodiment, such as one where the display assembly isbeing attached to the vulcanized rubber article by a consumer or thelike at a point subsequent to the manufacture of the vulcanized rubberarticle, the adhesive layer may be formed from a material capable offorming the desired chemical bond or being vulcanized thereto ambienttemperature conditions, e.g., by chemical reaction instead of being heatactivated. Such materials include but are not limited to chemicalcements common in retread applications, cyanoacrylate, epoxies,rubber-based acrylic pressure sensitive adhesives and combinationsthereof. Such application may also call for some degree of elevatedpressure being applied to the display assembly during adherence by theadhesive layer. In an example, such elevated pressure may be in therange of from about 3 to 10 Psi.

In an example, depending on the particular size and configuration of thedisplay assembly 20, it is desired that the adhesive layer 26 thicknessbe that which is sufficient to enable the adhesive layer to function inthe above-described manner. The exact thickness of the adhesive layer isunderstood to vary depending on the particular type of material selectedfor the adhesive layer as well as the particular end-use application. Inan example, the adhesive layer 26 may have a thickness greater thanabout 0.006 mm, from about 0.006 mm to 0.5 mm, 0.01 mm to 0.3 mm, 0.02mm to 0.1 mm, and in a particular example of about 0.04 mm.

In an example, the display assembly described above and illustrated inFIG. 2 may be made by joining the display layer and intermediate layertogether and then subjecting the same to vulcanizing conditions ofelevated temperature and/or pressure, after which time the adhesivelayer may be combined therewith, e.g., at the point of applying thedisplay assembly. While the example display assembly illustrated in FIG.2 has been disclosed as comprising three separate and distinct layers,it is to be understood one or both of the display layer or the adhesivelayer may be configured so as to include a barrier composition at aninterface therebetween that may operate to provide the barrierproperties noted above, thereby avoiding the need use three separate anddistinct layers for the display assembly.

FIG. 3 illustrates a second example display assembly 30 as disclosedherein comprising, moving from a surface portion of the display assembly30 to a portion attached to a vulcanized rubber article, a display layer32, an intermediate or barrier layer 36, and an adhesive layer 38.Unlike the example illustrated in FIG. 2 and described above, thedisplay layer 32 in this example is made up of two or more differentdisplay layers, e.g., a first or upper display layer 31 and a second orlower display layer 33.

In this embodiment, each display layer may be sized, shaped, patterned,colored and/or textured differently from the other to provide a desireddisplay indicia when combined together. For example, the first displaylayer 31 may be white in color and have a particular size, wherein thesecond display layer 33 may be black in color and be sized slightlylarger than the first display layer for purpose of providing a desireddisplay visual indicia. This is but one example of how the differentdisplay layers 31 and 33 can be used with one another to provide adesired display indicia. In another example, as noted above, the firstdisplay layer may be of one color and have one or more openings cut intoit, and the second display layer is of another color so such color isdisplayed through the openings to provide a desired visual indicia onthe surface of the display assembly. These are but a few examples of howthe first and second display layers can be used to provide a desireddisplay indicia for purpose of example and reference, and it is to beunderstood that all such variations are to be within the scope of thedisplay assemblies as disclosed herein. Also, while an examplecomprising two display layers has been disclosed, it is to be understoodthat display assemblies as disclosed herein may comprise more than twodisplay layers depending on the particular display indicia desired forthe particular end use application.

The display layers 31 and 33, as well as the intermediate layer 36 andadhesive layer 38 may each be formed from the same types of respectivematerials described above for the earlier examples. In an example, thedisplay layers 31 and 33 may have the same thickness as described above,so that the overall thickness of the display layer 32 is generallygreater than that of the earlier described examples. However, thethickness of the display layer 32 may also be less than or equal to thethickness of earlier described examples so as to meet the requirementsof a particular function or aesthetic desire. As noted above for theexample display assembly of FIG. 2, the example display assemblyillustrated in FIG. 3 may alternatively comprise a display layer oradhesive layer configured having a barrier composition at an interface,so as to avoid the need to obtain desired barrier properties through aseparate and distinct barrier layer.

In an example, the display assembly described above and illustrated inFIG. 3 may be made by joining the display layers, and intermediate layertogether and then subjecting the same to vulcanizing conditions ofelevated temperature and/or pressure, after which time the adhesivelayer may be combined therewith, e.g., at the point of applying thedisplay assembly.

FIG. 4A illustrates a third example display assembly 40 as disclosedherein comprising, moving from a surface portion of the display assembly40 to a portion attached to a vulcanized rubber article, a display layer48, an intermediate adhesive layer 50, an intermediate or barrier layer44, and an adhesive layer 46. The principle difference between thissecond example display assembly 40 and that disclosed above andillustrated in FIG. 2 is the presence and use of an intermediateadhesive layer 50 interposed between the display layer 48 and theintermediate or barrier layer 44. The presence of such an intermediateadhesive layer 50 in this second example operates to provide a greaterdegree of adhesion between the display layer 48 and the intermediatelayer 44, and may also operate to provide and extra degree of barrierprotection against the migration of any unwanted constituents from theintermediate layer 44, adhesive layer 46, and/or the vulcanized rubberarticle that the display assembly is attached to.

The materials used in this second example for the display layer 48,intermediate layer 44, and adhesive layer 46 may be selected from thesame types of materials described above for the first two examples. Thethicknesses of the display layer 48, intermediate layer 44, and adhesivelayer 46 may also be the same as that described above for the first twoexamples.

The intermediate adhesive layer 50 is formed from a material capable offorming a bonded attachment between and underside surface of the displaylayer 48 and a surface of the intermediate barrier layer 44, andoptionally acting as a barrier to minimize or prevent the migration ofany unwanted constituents into the display layer 48. In an example, theintermediate adhesive layer 50 is formed from a thermoset adhesive.Thermoset adhesives useful for forming the intermediate adhesive layer50 include and are not limited to heat vulcanizing cements common inretread applications, water-based or solvent based polymer polyurethanebased adhesives, epoxies and combinations thereof. In an example,depending on the particular size and configuration of the displayassembly 40, it is desired that the intermediate adhesive layer 50thickness be that which is sufficient to enable the intermediateadhesive layer to function in the above-described manner. The exactthickness of the intermediate adhesive layer is understood to varydepending on the particular type of material selected for the displaylayer and the intermediate layer as well as the particular end-useapplication. In an example, the intermediate adhesive layer 50 may havea thickness greater than about 0.006 mm, of from about 0.006 mm to 0.5mm, about 0.01 mm to 0.3 mm, and in a particular example about 0.025 mm.

In an example, the display assembly described above and illustrated inFIG. 4 may be made by joining the display layer, the intermediateadhesive layer, and intermediate layer together and then subjecting thesame to vulcanizing conditions of elevated temperature and/or pressure,after which time the adhesive layer may be combined therewith, e.g., atthe point of applying the display assembly. While the example displayassembly illustrated in FIG. 4A has been disclosed as comprising fourseparate and distinct layers, it is to be understood that one or more ofthe display layer, intermediate adhesive layer, barrier layer, or theadhesive layer may be configured as a composite having properties ofanother layer so as to reduce the total number of separate and distinctlayers used for making the display assembly 40. For example, theintermediate adhesive layer may be configured having a barriercomposition along an interface with the adhesive layer, thereby avoidingthe need to use a separate and distinct barrier layer, or the barrierlayer may be configured comprising an adhesive composition on or both ofits surfaces so as to avoid having to use one or more separate adhesivelayers. These are just a few examples of how composite compositions maybe used in such multilayer display assemblies to reduce the total numberof separate and distinct materials layers used while still providing allof the desired described properties.

FIG. 4B illustrates an example display assembly 42 that is somewhatsimilar to that illustrated in FIG. 4A, in that it comprises a displaylayer 45 on a top surface, an intermediate adhesive layer 47 below thedisplay layer. However, in this particular example, the display assembly42 includes a second or intermediate display layer 49 that is interposedbetween the intermediate adhesive layer 47 and the barrier layer 51, andlike in the third example an adhesive layer 53 is disposed beneath thebarrier layer. A feature of such construction is the ability toconfigure the uppermost display layer 45, e.g., shape, size and/orpatterning of openings or the like to reveal at least a portion of theintermediate display layer 49 to provide the desired display indicia.Also, in such an example, a sub assembly made up of the adhesive layer53, barrier layer 51, and intermediate display layer 49 may be made andcombined in the manner noted above and adhered to the desired substrateportion, e.g., a vulcanized rubber article. After such sub assembly hasbeen attached to the desired substrate, then the uppermost display layer45 may be attached thereto through the use of the intermediate adhesivelayer 47. The ability to construct the display assembly in this manner,through the use of a sub assembly and later applied display layer addsflexibility in being able to provide the desired display layer after aportion of the assembly has already been installed on the substrate. Italso allows for the subassembly to be manufactured and kept in stock asthe standard subassembly for a variety of different types of upper mostdisplay layers. An example of such a display assembly may include whitewalls, red walls, or other colored walls or other desired type ofindicia that may now be selected and applied after the standard stocksubassembly has been attached to the substrate.

FIG. 5 illustrates a fourth example display assembly 55 as disclosedherein comprising, moving from a surface portion of the display assembly55 to a portion attached to a vulcanized article, a display layer 52, anintermediate adhesive layer 54, an intermediate barrier layer 56, and anadhesive layer 58. Like the example illustrated in FIG. 3 and describedabove, the display layer 52 in this example is made up of two or moredifferent display layers, e.g., a first or upper display layer 57 and asecond or lower display layer 59. Like the example illustrated in FIG.4A and described above, the display assembly 50 comprises anintermediate adhesive layer 54 that is interposed between the displaylayer 52 and the intermediate barrier layer 56.

The intermediate adhesive layer 54 operates in the same manner asdescribed above for the example illustrated in FIG. 4A, to provide agreater degree of adhesion between the display layer 52 and theintermediate barrier layer 52, and may be formed from the same materialsand have the same layer thickness as that described above for theexample illustrated in FIG. 4A.

In an example, the display assembly 50 may be made by joining thedisplay layer, the intermediate adhesive layer, and intermediate layertogether and then subjecting the same to vulcanizing conditions ofelevated temperature and/or pressure, after which time the adhesivelayer may be combined therewith, e.g., at the point of applying thedisplay assembly.

FIG. 6 illustrates a fifth example display assembly 60 as disclosedherein comprising, moving from a surface portion of the display assembly60 to a portion attached to a vulcanized article, protective layer 62, adisplay layer 64 (comprising an upper display layer 67 and a lowerdisplay layer 69), an intermediate barrier layer 66, and an adhesivelayer 58. A feature of this example is the presence of a protectivelayer 62 that is disposed over the display layer, wherein the protectivelayer is formed from an optically transparent material and may be usedto enhance and/or protect the display layer from external elements thatmay damage or otherwise degrade the indicia provided by the displaylayer, thereby enhancing the service life of the display assembly. Whilethe protective layer has been disclosed in the context of being usedwith the particular display assembly construction as illustrated in FIG.6, it is to be understood that the protective layer may be used with anyand all of the display assemblies as disclosed herein.

In an example, the protective layer may cover the entire surface of theunderlying display layer, or display layers in the event the displayassembly comprises more than one display layer, or a partial portion ofthe display layer depending on the particular display indicia and/or theparticular end-use application. Materials useful for forming theprotective layer are preferably elastomeric, e.g., having the samedegree of flexibility or elasticity as that of the underlying displaylayer, and may be selected from materials including and not limited topolyurethane, vinyl, polyethylene terephthalate, rubber-basedelastomeric inks, and combinations thereof. In an example, depending onthe particular size and configuration of the display assembly, it isdesired that the protective layer thickness be that which is sufficientto enable the protective layer to function in the above-describedmanner. The exact thickness of the protective layer is understood tovary depending on the particular type of material selected for theprotective layer as well as the particular end-use application. In anexample, the protective layer may have a thickness greater than about0.006 mm, of from about 0.006 mm to 0.3 mm, about 0.01 mm to 0.2 mm, andin a particular example about 0.025 mm.

FIG. 7 illustrates a sixth example display assembly 70 as disclosedherein comprising, moving from a surface portion of the display assembly70 to a portion attached to a vulcanized article, a display layer 72, anintermediate adhesive layer 74, an intermediate barrier layer 76, and anadhesive layer 77, wherein a cavity 78 is disposed within the assemblyfor the purpose of accommodating an element or object 79 therein. Likethe example illustrated in FIG. 5 and described above, the display layer72 in this example is made up of two or more different display layers,e.g., a first or upper display layer 80 and a second or lower displaylayer 82.

A feature of this particular embodiment is the presence of a cavity 78that is formed in the display assembly 70 for the purpose ofaccommodating placement of an element or object 79 therein. For purposeof reference, a display construction somewhat similar to thatillustrated in FIG. 5 was used to disclose the cavity feature forpurposes of reference and example, and it is to be understood thatdisplay assemblies as disclosed herein comprising cavities may beembodied having other display assembly constructions as disclosedherein.

In this example, the cavity is formed within the second display layer 82and the intermediate adhesive layer 74 and is configured to accommodatea desired element or object therein, wherein such element or object maybe any type of rigid or non-rigid element, passive or non-passiveelement, functional or nonfunctional element that may be useful forincluding in the display assembly. Examples of the types of objects orelements that may be disposed in the cavity include RFID elements, GPSelements, lighting elements such as LEDs or the like, and the like. Inan example, the cavity is configured within the construction to providean area capable of accommodating such an element or object withoutdamaging the element or object, and without causing damage to thedisplay assembly itself during use of the vulcanized rubber article thatit is attached thereto. In the example illustrated in FIG. 7, the cavityis positioned beneath the first display layer 80, and if desired thefirst display layer may comprise one or more openings for the purpose ofdisplaying a portion of the object or element disposed within thecavity. It is to be understood that display assemblies comprising acavity as disclosed herein may include the cavity positioneddifferently, e.g., formed within one or more different assembly layers,than that illustrated in FIG. 7 depending on the particular displayassembly, the particular configuration of the cavity, the particularelement or object disposed within the cavity and its intended purposeand/or function, and/or the particular end-use application of thevulcanized article.

While the cavity feature of display assemblies has been disclosed withreference to particular examples and illustrations, it is to beunderstood that display assemblies as disclosed herein may beconstructed with the cavity positioned other than as disclosed orillustrated. For example, the design assembly may be configured with thecavity deposed along an outer portion of the assembly, which may be adisplay layer, in which case an element disposed within the cavity wouldbe viewable from outside of the display assembly. An example of such maybe one where a light element is disposed within the cavity for purposesof providing illumination or an illuminated visual effect or the likeoutside of the display assembly that is viewable from outside of thevulcanized article. In such example, the cavity may be open and exposedto the external environment, or a layer of transparent material or thelike may be optionally disposed thereover. This is but one exampleprovided for the purpose of illustrating how the cavity may bepositioned differently within the display assembly to enable a desiredfunction or purpose.

While the display assemblies as disclosed herein have been referenced byexample and illustration having certain features and/or characteristics,it is to be understood that display assemblies meeting the generalconstruction parameters as disclosed herein and having additionalelements are intended to be within the scope of display assemblies ascovered herein. For example, while display assemblies may be configuredto provide a desired display indicia or the like through the shape,design, configuration or the like of the one or more display layers,Display assemblies as disclosed herein may be configured to provide adesired display indicia through the use of printed, marked or other typeof provided feature that may be included in or on the display layer. Forexample, the display assembly may comprise a desired display indiciaprovided in the form of an ink symbol, letter, or other marking featureor object that is disposed on or into the display layer, which symbol,letter, or other marking feature or object may be a brand, logo or thelike.

Display assemblies as disclosed herein may have a different totalthickness depending on the particular construction features within thedisplay assembly. In an example, the display assembly may have a totalthickness, as measured from a top surface of the display assembly(adjacent the display layer or protective layer) to a bottom surface(adjacent the adhesive layer) of greater than about 0.0025 mm, fromabout 0.0025 mm to 10 mm, from about 0.01 to 5 mm, about 0.1 to 3 mm,and in a particular example about 0.4 mm. It is to be understood thatthe exact thickness of the display assembly can and will vary dependingon the particular display assembly construction and/or end-useapplication.

Display assemblies as disclosed herein may be constructed to accommodatedifferent conditions for applying the display assembly to a desiredvulcanized rubber article, e.g., to accommodate application duringmanufacturing of the vulcanized rubber article, or to accommodateapplication after the vulcanized rubber article has been made. In anexample, display assemblies may be attached to a surface of a vulcanizedrubber article, e.g., a sidewall surface of a pneumatic tire, byreaction that may include and not be limited to heat and/or pressureand/or chemical bonding so as to provide a desired aesthetic appeal inthe form of desired visual indicia, such as lettering and/or otherobjects or shapes or designs and/or functional use, such as with barcoding or RFID technology, capable of withstanding the tire manufacturerrecommended life cycle. In an example, the element or object disposedwithin the cavity and affixed to the vulcanized article via the displayassembly as disclosed herein may have compatibility programmablefunctionality, such as RFID read/write capability, circuitboard/programmable system which can control a device such as a lightelement like an LED in a predetermined manner. Such functionality may beinnate with the element disposed in the cavity or may be controlled by aseparate component whether connected by wire or wirelessly, e.g.,blue-tooth enabled, radio controlled or other frequency connection. Inan example, the cavity may be configured within the display assembly toaccommodate a light element there, such as one or more LEDs therein, sothat the display assembly emits light that can be seen by a personlooking at the vulcanized article. In an example, the light element maybe controlled to provide a desired illumination.

FIGS. 8A to 8H illustrate different steps useful for applying thedisplay assembly according to an example method of applying. Referringto FIG. 8A, in an example method of applying, the intended or targetsurface 92 of the vulcanized rubber article 90 is cleaned so as toremove any dirt, oil, debris or other foreign agents or containmentsthat could interfere with forming a desired attachment bond with thedisplay assembly. A suitable cleaning solution 94 or preparation agentcan be used for this purpose. In an example, such cleaning solution 94can be selected from but not limited to the group of organic orinorganic solutions such as acetone or the like. In an example, thecleaning solution 94 can be applied and used to clean the surface by useof a fabric material 96 or the like. As illustrated in FIG. 8C, in anexample, it may be desired to further treat the surface 92 by rougheningthe surface through the use of an abrasive means 104 such as sand paperor the like until the surface displays a rough texture, and thencleaning the treated surface, e.g., with the cleaning solution, toensure that it is free of any surface debris from the treatment process.

Referring to FIG. 8B, in certain applications, it may be desired to usea stencil 98 or template for the purpose of properly/accurately locatingthe display assembly on the surface of the vulcanized rubber article.For example, in the case where a series of the display assemblies are tobe applied to a sidewall surface of a tire to provide a desired stringof letters, numerals and/or designs or the like, a stencil 98 ortemplate may be used to ensure that the display assemblies arepositioned at a proper spacing and/or at a proper location along thesidewall surface. The stencil 98 may be provided in the form of asemi-rigid material such as paper, plastic film or the like that can beapplied to the target surface. As shown in FIG. 8C, the stencil 98 canbe removably attached to the target surface 92 or held in place by hand.Referring back to FIG. 8B, in an example, the stencil 98 or templatecomprises a pressure sensitive adhesive backing and is prepared foradhered placement against the target surface by removing a carrier sheet100 covering the adhesive and pressing the stencil into contact with thetarget surface 92 at the desired position to ensure an adequate bond,specifically around the cut out areas in the stencil (as best shown inFIG. 8C). Referring to FIG. 8C, in an example where a stencil 98 ortemplate is used, the steps of treating the target surface 92 by sandingor the like and then cleaning the treated surface is preferably doneafter the stencil has been placed into position, thereby limiting thetarget surface area 102 being prepared to only that exposed by the cutout areas 106 of the stencil 98. FIG. 8D illustrates the target surfaceareas 102 of the sidewall as treated by sanding with the template 98still in place.

Alternatively, instead of using a separate stencil for purposes ofapplying the display assembly in a desired arrangement, the displaceassembly may be configured having a transfer carrier adhered to an uppermost surface of the display assembly, wherein the display assembly ispositioned on the transfer film in a desired arrangement for placementonto the target surface without the use of a stencil to provide the avisual display having the desired arrangement.

Referring to FIGS. 8E and 8F, a desired adhesive material 110, selectedfrom the materials described above, is applied to the treated surface102 by suitable means, which can be by spray, roll, brush 104 or thelike to form a desired thickness of the adhesive layer to receive thedisplay assembly. In example where a stencil 98 is used, the adhesive104 is applied to the cut out section or sections 106 and the template98 is removed before the adhesive cures so as to avoid difficulttemplate removal. FIG. 8F illustrates the treated surfaces coated withadhesive material 110 after with the template removed, wherein thetreated surfaces having the adhesive material is in the form of a seriesof letters. Alternatively, or in addition to the method of adhesiveapplication disclosed above, the adhesive may be applied to theunderside surface of the display assembly that is then applied to thetarget surface.

In an example, the adhesive material once applied to the target surfaceis allowed to dry for a predetermined period of time, which amount oftime can and will vary depending in the particular type of adhesivematerial used. In an example, the adhesive material that is used isHeavy Duty Blue Vulcanizing Fluid by Tech International and it isallowed to dry for a period of approximately 20-30 minutes. Referring toFIGS. 8G and 8H, once the adhesive material 110 has dried for thedetermined time, the display assembly 112 is placed onto the adhesivematerial layer 110. In an example, the display assembly 112 is pressedinto contact with the adhesive layer and target surface by using astitching tool, whereby moderate pressure is applied onto the displayassembly by rolling the stitching tool over the entire surface area ofthe display assembly to ensure complete bonding and adherence betweenthe display assembly and the vulcanized rubber article by the adhesivelayer. FIG. H illustrates a number of the display assemblies 112attached to respective target surfaces containing the adhesive material.In the example where a transfer carrier is used rather than the stencil,once the display assembly is applied to the target surface and bondedthereto, the transfer carrier is removed from the display assembly,having served its purpose to provide the display assembly in a desiredform, configuration or arrangement on the target surface.

In an example, it is desired that the so-applied display assembly beallowed to cure for a predetermined amount of time before the vulcanizedrubber article is placed into use. For example, when the article is atire sidewall, it is desired that the display assembly be allowed tocure for at least 8 hours before a vehicle comprising the tire or tiresare operated. In an example, ideally it is desired that the displayassembly be allowed to cure for 24 hours before the vulcanized articlein the form of tires are operated.

In another example method, display assemblies as disclosed herein may beapplied to a desired vulcanized rubber article at the point ofmanufacture. In an example, wherein the vulcanized rubber article is atire, display assemblies may be applied in a similar manner as disclosedabove, with a difference being that the adhesive material may beprovided in the form of a heat-activated material, in which case oncethe adhesive material is applied to the target surface heat is used tocause the display assembly to be adhered thereto. In such example,pressure may also be applied by suitable machinery as the adhesivematerial is curing to ensure a desired bonding occurs between thevulcanized rubber article and the display assembly.

While the display assemblies and method of applying the same asdisclosed herein have been presented with respect to the described andillustrated embodiments, it is to be understood that the disclosure isnot to be limited to those alternatives and described embodiments.

What is claimed is:
 1. A display assembly for attachment with avulcanized rubber article comprising: one or more display layers ofelastomeric material configured to provide a display indicia; anintermediate layer formed from an elastomeric material that is differentfrom that of the one or more display layers; and an adhesive layer,wherein the intermediate layer is interposed between the adhesive layerand the one or more display layers, the adhesive layer being formed froma material capable of chemically bonding with a surface of a vulcanizedrubber article.
 2. The display assembly as recited in claim 1 comprisinga first display layer and a second display layer disposed beneath thefirst display layer.
 3. The display assembly as recited in claim 2wherein the first display layer is colored differently from the seconddisplay layer.
 4. The display assembly as recited in claim 1 furthercomprising an intermediate adhesive layer interposed between the one ormore display layers and the intermediate layer.
 5. The display assemblyas recited in claim 2 further comprising an intermediate adhesive layerinterposed between the second display layer and the intermediate layer.6. The display assembly as recited in claim 1 further comprising aprotective layer disposed over the one or more display layers andforming an outermost surface of the display assembly, the protectivelayer formed from an optically transparent material.
 7. The displayassembly as recited in claim 1 further comprising a cavity disposedtherein.
 8. The display assembly as recited in claim 7 furthercomprising an element disposed within the cavity.
 9. The displayassembly as recited in claim 5 wherein the cavity is disposed beneaththe one or more display layers.
 10. The display assembly as recited inclaim 2 wherein he first display layer include one or more openingstherethrough, and wherein the second display layer is visible throughthe one or more openings.
 11. A method for attaching a display assemblyto a surface of a vulcanized rubber article comprising the steps of;preparing a surface of a vulcanized rubber article by cleaning thesurface; applying an adhesive material to form an adhesive layer;placing a display assembly into contact the surface with the adhesivelayer interposed therebetween to form a bond between the displayassembly and surface, the display assembly comprising: one or moredisplay layers of elastomeric material constructed to provide a displayindicia; and an intermediate layer formed from an elastomeric materialthat is different from that of the one or more display layers; whereinthe intermediate layer is interposed between the adhesive layer and theone or more display layers, the adhesive layer being formed from amaterial capable of chemically bonding the display assembly to thesurface of the vulcanized rubber article.
 12. The method as recited inclaim 11 further comprising treating the surface to roughen the surfacebefore the step of placing.
 13. The method as recited in claim 12further comprising applying a template to the surface before the step ofapplying the adhesive material, wherein the template has a cut outsection and wherein, during the step of applying, the adhesive materialis applied to the surface exposed through the cut out section.
 14. Themethod as recited in claim 11 further comprising applying pressure tothe display assembly after the step of placing.
 15. The method asrecited in claim 11 wherein further comprising the step of heating theadhesive material after the step of applying.
 16. The method as recitedin claim 11 wherein the display assembly comprises a transfer carrierdisposed on the one or more display layers and, wherein after the stepof placing, the transfer carrier is removed from the display assembly.17. The method as recited in claim 11 wherein after the step of placing,a further display layer is placed onto the one or more display assemblydisplay layers and an adhesive layer is interposed between the furtherdisplay layer and the display assembly.
 18. The method as recited inclaim 11 wherein the vulcanized rubber article is tire, and wherein thesurface is a sidewall surface of the tire.
 19. A vulcanized rubber tirecomprising: a target surface disposed along a portion of the rubbertire; a display assembly disposed onto the target surface andcomprising: a display layer of elastomeric material; an intermediatelayer formed from an elastomeric material different from that of the oneor more display layers; and an adhesive layer interposed between thetarget surface and the intermediate layer bonding the display assemblyto the target surface.
 20. The rubber tire as recited in claim 19wherein the display layer comprises two display layers, and wherein thetwo display layers are configured within the assembly to provide adesired display indicia.